3-fabric layer insulation material and a method and an arrangement for producing the same

ABSTRACT

This invention describes a 3-layer insulation material comprising a first fabric layer, a second fabric layer and a third fluted intermediate fabric layer between the first and the second fabric layers, the fluted intermediate fabric layer being attached alternately to the first and the second fabric layer with longitudinal seams forming longitudinal channels for the insulation material having individual insulation material bundle inside each longitudinal channel. Also disclosed are a method and an arrangement for producing the same.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of and claims priority toU.S. patent application Ser. No. 16/608,216, filed on Oct. 25, 2019, nowU.S. Pat. No. 11,267,222, which claims priority to and the benefit ofU.S. national application of the international application numberPCT/FI2018/050319 filed on May 2, 2018, which claims priority to and thebenefit of Finnish application FI20175390, filed on May 4, 2017, theentire contents of all of which are incorporated herein by reference.

Disclosed invention relates to a 3-fabric layer thermal insulationmaterial with corrugated middle layer wherein a multiplicity of sliverinsulation is guided individually to multiplicity of fabric length wiserunning corrugated bundle channels. Insulation is not attached to fabricbut is floating in bundle channels merely by friction between insulationand fabric walls. Insulation is specially designed for garment, quilts,sleeping bags and the like. Also disclosed are a method and anarrangement for producing the same.

In U.S. Pat. No. 2,607,104 is described a corrugated two-ply andthree-ply fabric a highly resilient for lateral compression. Elasticresistance of this fabric to lateral compression is described to providecushioning comparable to sponge rubber. The three-ply fabric comprises atop fabric, bottom fabric and much stiffer intermediate fabric which iswoven on a single operation. In order to form three dimensional shapesthe top and bottom fabrics are shrunk by heat treatment. Non-shrinkingintermediate layer will form a corrugated fabric layer. In order to openthe channels for filling the shrinking process must be done afterweaving. Therefore, if industrially possible at all, the filling wouldbe a separate operation for the insulation material after weaving andshrinking of the fabrics. However the material disclosed in the documentis constructed to keep corrugated passages open by stiffer intermediatelayer even under substantial pressure. Producing three layer fabrics isalso uneconomical and if any insulation is introduced to the process itshould be done in weaving process, which is not found in description.

Insulating properties could be increased by filling corrugated channelswith insulating fibers. U.S. Pat. No. 2,607,104 suggests to fill strandswith blowable rubber-like material like vinyl chloride strips whichwould expand under heat and fill the channels or alternatively use glassfibers. Even if the document suggests filling the channels withinsulating material it does not provide information how to do itindustrial manner nor suggest that material would be suitable forgarment making.

GB 1,390,609 describes a thermal insulating material which has twolayers of sheet material with two sheets of insulating material eachinsulating material attached by stiches to on one of the layers forminga composite insulation material. The corrugated, e.g. grooved, surfacesare coupled together with peaks of corrugation, which on one section aredispersed in the folds of corrugations of the other sections so that thelines of stitching in one section do not overlap those in the othersection whereby the two sections together provide a composite insulationmaterial having a uniform insulation over the width of the materialwithout cold bridges caused by needle holes. However insulation materialis missing a third intermediate fabric layer which would couple the twolayers of sheet material together and provide additional air-seal layer.In its simplest form the insulation is merely two ordinary quiltedinsulation material placed together back to back and kept togethermerely with natural adhesion and surface irregularities.

An apparatus manufactured by applying the alternate quilting method hasbeen disclosed in US 2014-0250575A. Multiple layers may be arranged inlayer sets, the layers of each layer set may be quilt-stitched to eachother, and as a result, stitches may be formed. A space between thelayers of each layer set may be filled with a thermal insulationmaterial. The layer sets may be offset with respect to each other, inorder for the stitches of one layer set to be blocked by the area ofanother layer set abundant with the insulation material, the objectiveof which is to block flow of cold air from needle holes through thealternate quilting construction. This is expensive solution since twolayers of insulation need to be quilted and parts has to be carefullyplaced in appropriate position related to each other's.

U.S. Pat. No. 3,805,720 describes a quilted construction with specialseam construction, i.e. inwardly turned tuck which would precludeabrasion, snagging, pulling the stitching line. Sewing of thisconstruction can only be done by individually sewn every seam and is notapplicable for production by quilting machine.

WO 2014/190319 A1 discloses insulating materials including a liningmaterial layer, a face material layer, at least one layer of continuoussynthetic insulation disposed between the lining material layer and theface material layer, fill is disposed between the lining material layerand the face material layer, one or more first seams are coupling thelining material layer and the at least one layer of continuous syntheticinsulation, and one or more second seams are coupling the face materiallayer and the at least one layer of continuous synthetic insulation. Thefirst and second seams form two or more baffles partitioning the fill inthe insulating material. The document describes a continuous insulationlayer which is traditional sheet material. Face material layer is to beattached to insulation layer by stitching, welding or clueing i.e.bonding with adhesive. Additional second insulation material is addedbetween insulation material and face material layer and insulationmaterial and lining layer. For example a fill, e.g. feathers aerogel,wool or flannel is disposed between the face material layer and liningmaterial layer or between. Continuous insulation layer may bestabilizing the positioning of the additional second insulationmaterial, i.e. fill, reducing the loose fill migration. This documentdoes not disclose how the additional second layer e.g. down is added.Traditionally the down is tucked by hand to every compartment filing onecompartment at time which is labor consuming and expensive.

U.S. Pat. No. 5,713,079 A presents an insulated garment wherein thefirst layer of insulation is sewn to the first fabric layer and secondlayer of insulation is sewn to second fabric layer by stitching. Theremay be a lining layer on back side of both insulation layers. Insulationlayers are displaced so that midpoint of array of stitching covers thearray of needle holes of the counterpart insulation layer. Theinsulation comprises goose down on first layer and second layer is madeof synthetic material. Object of invention is to get beneficial effectof both materials. When using this type of insulation the garment needto be uniquely configured to have midpoint of first insulation layer tocover stitching of second insulation layer. Since user have severaldifferent body types the garment may hang freely or may need to contourto cover the torso shape. The position of outer layer related to innerlayer will variate greatly thus resulting displacement of insulation.

In garment manufacturing there are two elements that are important inprotecting from the cold: stopping the wind from penetrating andmaintaining the layer of warm air close to the body by the use of fibersto create a layer of still air which serves as an insulation.

Air is commonly used non-conducting insulator. A window's thermalinsulation is improved by increasing window panes and isolating airlayers between panes. Window with three window panes have higherinsulation than window with two panes. Therefore having three fabriclayers in garment insulates better than garment with only two layers offabric.

The present invention describes a material with three layers of fabric;each layer has substantially low air permeability, preventing air fromtraveling through fabric layers to the next bundle channel. This stopswarm air from escaping out of insulation and prevents occupation of coldair inside of insulation. A fiber sliver, e.g. a continuous crimped tow,is inserted to float freely inside bundle channels between fabric layersto keep layers separate, trapping in warm air emitted from the user'sbody. This solution produces superior insulating abilities over two- orsingle fabric layer insulation.

Traditionally insulation material in garments is introduced to thequilting machine as sheet material. Insulation is instructed between theface layer and the lining layer and sewn together with an array ofneedles. Needle holes produce cold bridges, i.e. thermal bridges. Coldbridges form weak spots in the insulation, causing cold air from outsideof the garment to migrate inside of the garment. In one embodiment ofthe invention is used laser welding, which makes it possible to attachtwo fabric layers together without needle holes. Additionally laserwelded seams provide barrier to particles, liquids and gases. Thefabrics are welded together from only interconnections, so the surfaceof the fabric stays intact.

The manufacturing of the continuous insulation sheet material involvesspecially engineered methods and processes, which adds expenses to theprice of insulation. Instead of using traditional sheet material asinsulation layer, present invention uses continuous fiber-bundleinsulation, i.e. the sliver of fiber, a strand of loose, untwisted ropeof fibers, continuous, possibly crimped tow, directly extruded fromspinneret as multiplicity of continuous filament strands. The spinnerethas tiny holes through which a chemical solution is extruded to producecontinuous filaments, as of polypropylene, nylon, or polyester. Multiplefiber filaments form a continuous bundle tow.

The sliver can also be made via a carding process, which forms a lightlycoiled, puffy strand of fibers can be a product of the fiber combingprocess. The sliver could be introduced directly from collection barrelsto fill the fabric lengthwise, running longitudinal along bundlechannels. The sliver is attached inside of a bundle channel possiblyonly by friction. Eventually it will be anchored in its place from itslongitudinal ends, when the insulating material is cut and sewn to be agarment. This direct method skips the manufacturing processes, whichthen simplifies whole process making insulation more economical.

Quilting fabric with needles is a slow and a labor intensive process,which has made quilting uneconomical in many parts of the world. Thebonding of layers with an adhesive is a process where two or moredissimilar substances are united by molecular force acting in the areaof contact. This process requires the melting and cooling of adhesive isproduction which is a time consuming process. Due to the limited peelstrength, the adhesive-bonded seams often delaminate when continuousbending and washing. Laser welding on the other hand is economical andhighly productive. Compared to traditional quilting methods by stitchingor adhesive bonding, laser welding could easily multifold the speed.Increased production would have a remarkable economic impact.

To produce good quality seams using laser welding requires an infra-redabsorbing textile, and another textile which does not absorb infra-redradiation. Laser energy percolates through the non-IR absorbing layer oftextile and is absorbed by the underlying IR-absorbing textile. Thefabric layers are melted together on a molecular level under pressurefrom pressure roller. In the laser welding process, the outer surface ofthe fabric is not affected, only the thin layers of the fabric ininterconnection is melted. Therefore, the surface or fabric is notaffected.

Alternatively, in other embodiments, ultrasonic seaming could be used,however that method would melt the seam throughout which might beundesirable for some.

Laser-welded seams do not use additional adhesive in the joint. Laserwelding results in a joint which has greater flexibility and a softerfeel compared to adhesive bonding. The IR-absorbency of the fabric canbe reached by having the fabric itself being IR-absorbent. The fabriccan also be dyed or printed to be IR-absorbent, or IR-absorbent can beapplied to a seam before welding e.g. by spraying. Welding requiresequal thermoplastic properties, so therefore e.g. polyester fabric isthe most suitable to be welded with polyester; polypropylene withpolypropylene; and polyamide with polyamide. Suitable laser weldingheads, which can be adopted to use in fabric welding, are developed forexample by Leister Technologies AG, CH-6056 Kaegiswil, Switzerland andTWI Ltd, Cambridge, United Kingdom.

In the following the invention is discussed more precisely referring todrawings where,

FIG. 1 shows a cross sectional view of the 3-layer insulation withcorrugated middle layer,

FIG. 2 shows a cross sectional view of a laser welding machine beingable to make corrugated insulation,

FIG. 3 shows a cross sectional view of a laser welding machine in openposition,

FIG. 4 shows a side elevational view of the laser welding machine andthe material flow in the machine,

FIG. 5 shows a perspective view of a laser welded seam, and

FIG. 6 shows a garment and the placement of a piece of insulationmaterial as part of garment.

FIG. 1 shows a cross sectional view of a 3-fabric layer corrugatedinsulation material 10 with a first fabric layer 12, second fabric layer14 and fluted third intermediate fabric layer 16 joined togetherlongitudinally by multiplicity of lengthwise welded seams 18 a-18 n.First fabric layer 12 and third intermediate fabric layer 16, andrespectively on reverse side second fabric layer 14 and said thirdintermediate fabric layer 16 form a plurality of bundle channels 20which are individually filled with insulation material 22. The fabriclayers 12, 14 and 16 can be different type of textile material, e.g.woven, knitted, warp knitted, felt, or nonwoven material.

FIG. 2 shows a laser welding machine 24, which is able to makeinsulation material 10 (FIG. 1 ). The machine 24 has an upper frame 26,which houses an upper fabric guide 30 guiding the first fabric layer 12and a lower frame 28 housing a lower fabric guide 32 guiding the secondfabric layer 14. Third fabric layer 16 is directed between upper flutingfolder 34 which is attached to said upper frame 26 and a lower flutingfolder 36, which is attached to said lower frame 28. Multiplicity oflaser sources 38 are attached to said upper frame 26 above multiplicityof welding stations 24 a-24 n and a multiplicity of laser sources 38 areattached to said lower frame 28 below multiplicity of welding stations24 a-24 n.

The multiplicity of said laser sources 38 are shown only symbolically.The function and design of laser welding have already been disclosed ina variety of publications with respect to the laser transmission weldingmethod, which is therefore common knowledge to a person skilled in theart, such that they need not be described in more detail here. Thereforethe depiction of the laser light source from which the laser light 38originates has been omitted.

When the first fabric layer 12, the second fabric layer 14 and the thirdfabric layer 16 are pulled, rolled or otherwise moved forward, the firstlayer of fabric and said intermediate layer and on reverse side saidsecond layer of fabric and said intermediate layer are longitudinallymelted together on a molecular level by laser sources 38 along seams 18a-18 n (FIG. 1 ). A multiplicity of hollow conduits 42 are installed infront of the folders 34 and 36. Insulation material 22 is simultaneouslywith welding introduced inside the bundle channels 20 through theconduits 42. Even if the hollow conduit 42 is preferred embodiment alsoother means can be used to guide insulation tow to cavities/bundlechannels 20. Guiding means like rings, channels, ducts and tubes can beused. These all among others are widely used in textile industry and arecommon knowledge to the person skilled in the art.

FIG. 3 shows a laser welding machine 24 in open position. In thisposition, the machine can be cleaned and served and the third layer offabric 16 can be inserted between the upper fluting folder 34 and thelower fluting folder 36.

FIG. 4 shows a side elevational view of the welding machine 40 and thematerial flow in welding machine. The first fabric layer 12 isintroduced to welding machine 40 from roll 48, the second fabric layer14 is introduced to the machine from roll 50 and the third intermediatelayer of fabric 16 is introduced to machine from roll 52. The powersource (not shown) is connected to roll 46 and is pulling the insulationmaterial 10 through the machine and storing the insulation material 10on roll 46. Alternatively other fabric moving methods can be used,including pressure rolls connected to a motor or fabric pullers behindwelding frames.

Simultaneously when fabric is moved through the machine, the pluralityof bundle channels 20 (FIG. 1 ) are individually filled with insulationmaterial 22 a-22 n, introduced through said multiplicity of conduits 42a-42 n. The first fabric 12 from roll 48 and the second fabric 14 andthe third fabric from roll 52 are introduced between folders 34 and 36,and are welded together longitudinally by a multiplicity of weldingstations 24 a-24 n.

In order to absorb IR-light optimal energy, a laser absorber 54 a and 54b can be introduced to fabric in a joint before welding fabric. Theabsorber can be e.g. sprayed on a weldable part of the fabric layerthrough nozzles 56 and 58. Commercial IR-absorbers are made by, forexample, Centex Corporation under the Clearweld name. An IR absorber canalternatively be included to a polymer solution before extrusion,printed, coated, or otherwise applied on the fabric.

In an embodiment where heat adhesive is used to join the fabric layersthe adhesive can be sprayed or other way conducted to the joint areathrough the nozzles. Adhesive can be in liquid form or it can be appliedas continuous filament.

It is also possible to use different laser welding methods foralternative embodiments of the invention. In laser welding, instead ofusing multiple laser heads to perform multiple contour welded seamsthere is an option to use only one laser head to produce all the seamssimultaneously. There are three main techniques know in industry whichcould be utilized with current invention:

Diffractive Welding

Diffractive optical element (DOEs) shape and split laser beams in anenergy-efficient manner. Diffractive beam splitter, included to thelaser source is a single optical element that divides an input beam intoN output beams 29. Output beams can be pointed to predeterminedpositions. The light laser beam 29 is split and simultaneously directedto joint fusion areas 18 a-18 n with minimal light loss.

Scanner Welding

In scanner welding the beam guidance is performed by using mobilemirrors included to laser source 38. The beam 29 is directed by changingthe angles of the mirrors. The beam continuously scans the welding areas18 a-18 n at very high speed. The fabrics passing through the weldingareas will be melted and fused from the joint areas quasi-simultaneouslymanner.

Mask Welding

Mask welding method utilizes wide beams that moves over the entiresurface being welded. Mask shields are protecting areas where welding isnot desired. Predetermined welding seam areas 18 a-18 n will be meltedand fused.

The function, design, use and mode of operation of mask welding,diffractive welding and scanner welding have already been disclosed in avariety of publications of the prior art with respect to the lasertransmission welding method, which is known per se, and are thereforecommon knowledge to the person skilled in the art, such they need not bedescribed in more detail here.

FIG. 5 shows a laser-welded seam, where fabric layer 12 is percolatingIR radiation, and where the IR absorbent middle layer of fabric 16 isapplied and absorbed with IR radiation 29, then heated, melted andpressed together with pressure 25 a and 25 b. A controlled amount ofheat is applied to the fabric joint. Laser energy passes through the IRpercolating fabric layer 12, heats the surface of IR-absorbent fabriclayer 16, melts the surface of layer 16, and seals the interface areatogether under pressure 25, hence forming a welded seam 18, when fabricis moved to direction 27. Pressure is forced between the pressurerollers 23 (FIG. 2 and FIG. 3 ) and the peaks of the fluting folders 34and 36 (FIG. 2 and FIG. 3 ).

In preferred embodiments of the invention the pressure can be applied tothe fabric with different methods, such as:

Pressure Plates

In preferred embodiment the fusible fabric layers, 12 and 16 on firstside and 14 and 16 on second side, are passing through and pressedbetween peaks of upper fluting element 34 and IR-transparent pressureplate (not shown) between laser source and first fabric layer on firstside and peaks of lower fluting folder 36 and IR-transparent pressureplate (not shown) between laser source and second fabric layer on secondside. The guide elements 30 and 32 are located on top of fluting foldersand are similar on upper guide elements and lower guide elements. Laserlight is applied to the welding positions through the laser lighttransparent pressure plates.

Pressure Roller

In one embodiment the pressure can be applied by a laser beamtransparent glass roller.

Pressure Ball

In one embodiment the pressure can be applied through a laser lighttransparent sphere which can be supported by air bearing which enablesfrictionless rotation.

The advantage of employing roller or sphere instead of plate is havingless friction and therefore less heat between pressure means and fabricwhen the fabric is moved thorough the welding station.

Pressure for welding stations can be produced mechanically, or as analternative, hydrostatically or pneumatically either blowing positivepressure or by suction production procure adhesion and connection offabrics in welding areas.

The function, design, use and mode of operation of pressure forming,have already been disclosed in a variety of publications of the priorart with respect to the laser transmission welding method, which isknown per se, and are therefore common knowledge to the person skilledin the art, such they need not be described in more detail here.

Different pressure sources in context of laser welding are described forexample in US patent application US 2014/0363636 A1 for LeisterTechnologies AG.

FIG. 6 shows a garment 60, and the placement of a piece of insulationmaterial as part of the garment. Insulation material 22 is floatingunattached to any of the fabric layers 12, 14 or 16. When the piece ofgarment is sewn to another piece of garment, like in shoulder seam 62joining the front part to the back part the insulation material will besecured in its place in the garment making process by a garment maker.

In one embodiment the materials can be selected from groups which arefire retardand. FR-insulation can be used in potential fire hazardousarea applications.

In these above embodiments there are described the use of laser-weldedseams. It is also possible to use conventional seams which are made bystitching. Also the seams can be ultra sound welded seams or adhesivebonded seams.

Although the invention has been shown and described with respect tocertain preferred embodiments, it is obvious that equivalents andmodifications may occur to others skilled in the art upon the readingand understanding of these specifications. The present inventionincludes all such equivalents and modifications, and is limited only bythe scope of the following claims.

LIST OF REFERENCE NUMERALS

-   -   10 insulation material    -   12 first fabric layer    -   14 second fabric layer    -   16 third intermediate fabric layer    -   18 a-18 n welding seams (lengthwise connections)    -   20 a-20 n bundle channels    -   22 insulation material    -   23 pressure roller    -   24 a-24 n welding stations    -   25 a, 25 b pressure    -   26 upper frame of machine    -   27 welding direction    -   28 lower frame    -   29 laser beam    -   30 upper guide elements    -   32 lower guide elements    -   34 upper fluting folder    -   36 lower fluting folder    -   38 laser source    -   40 welding machine    -   42 a-42 n multiplicities of conduits    -   44 intentionally blank    -   46 newly made insulation material storage roll    -   48 fabric storage roll    -   50 fabric storage roll    -   52 intermediate fabric storage roll    -   54 laser absorber    -   56 nozzles    -   58 nozzles    -   60 Garment    -   62 shoulder seam of garment

The invention claimed is:
 1. A 3-layer insulation material comprising afirst fabric layer, a second fabric layer and a third flutedintermediate fabric layer between the first and the second fabriclayers, the third fluted intermediate fabric layer being attachedalternately to the first and the second fabric layer with longitudinalseams forming longitudinal bundle channels for insulation material, andan individual insulation material bundle inside each longitudinal bundlechannel, wherein the longitudinal seams are laser welded seams and thefirst fabric layer and the second fabric layer are infrared radiationtransparent fabric and the third fluted intermediate fabric layer isinfrared radiation absorbing fabric.
 2. The 3-layer insulation materialof claim 1, wherein the third fluted intermediate fabric layer is madeinfrared absorbing by applying an infrared absorber on the third flutedintermediate fabric layer.
 3. A method for producing a 3-layerinsulation material comprising the steps of: introducing a first fabriclayer, a second fabric layer and a third fluted intermediate fabriclayer between the first and the second fabric layers, the first fabriclayer and the second fabric layer being infrared radiation transparentfabric and the third fluted intermediate fabric layer being infraredradiation absorbing fabric, and attaching the third fluted intermediatefabric layer alternately to the first fabric layer and the second fabriclayer to form a plurality of longitudinal bundle channels, wherein thefirst fabric layer and the second fabric layer are attached to the thirdfluted intermediate fabric layer by laser welding.
 4. The method forproducing the 3-layer insulation material of claim 3, whereinsimultaneously with the forming of said longitudinal bundle channelseach bundle channel is filled with a separate insulation materialbundle.
 5. The method for producing the 3-layer insulation material ofclaim 3, wherein the third fluted intermediate fabric layer is madeinfrared radiation absorbing by applying an infrared absorber on thethird fluted intermediate fabric layer.